Apparatus and method for weaving axminster fabrics



Aug. 27, 1957 H. HUGHES 2,804,096

APPARATUS AND METHOD FOR WEAVING AXMINSTER FABRICS Filed Nov. 9, 1e55 5 Shets-Sheet 1 INVENTOR 23y ,dm amw 1957 H. HUGHES 2,804,096

APPARATUS AND METHOD FOR WEAVING AXMINSTER FABRICS Filed Nov. 9, 1955 5 Sheets-Sheet 2 INVENTUR HflHRY HUG/1E5 H. HUGHES Aug. 27, 1957 APPARATUS AND METHOD FOR WEAVING AXMINSTER FABRICS Filed Nov. 9, 1955 5 Sheets-Sheet 3 Aug. 27, 1957 H. HUGHES 2,804,

APPARATUS AND METHOD FOR mvmc AXMINSTER FABRICS Filed Nov. 9, 1955 5 Sheets-Sheet 4 INVENTOR H/IRR r H06 H55 Aug 27, 1957 H. HUGHES 2,804,096

APPARATUS AND METHOD FOR WEAVING AXMINSTER FABRICS Filed NOV. 9, 1955 5 Sheets-Sheet 5 51 H1 A m? E h 50- I 50- 47) M I j h [h 4 I 03 I I H l H I! 3H i 51 63 EH17. a s a a v L I I INVENTOR m 6 ff/RRX Hue/955' T1 5. 18. 2 F

United States Patent APPARATUS AND METHOD FOR WEAVING AXMIYSTER FABRICS Harry Hughes, Toronto, Ontario, Canada, assignor to Toronto Carpet Manufacturing Co. Limited Application November 9, 1955, Serial No. 545,974 14 Claims. (Cl. 139-7) This invention relates to improvements in Axminster looms, and more particularly to an improved reed structure for such looms.

In conventional looms for weaving Axminster carpet a serious Waste of the pile forming yarn occurs as, in order to compensate for the inherent slippage of the pile yarn from between the weft shots during yarn draw off from the tuft tubes, an excessive length of yarn is inserted between the weft shots. When the depending legs of the pile yarn are turned or combed upwardly to form the carpet pile, these upturned leg ends are cut off so that the longest leg ends which occur as a result of a minimum of slippage of individual yarns or rows of yarn are reduced in length to the length of the shortest leg ends which occur as a result of maximum yarn slippage.

In an effort to eliminate low pile rows a substantial average length of the upturned tuft ends must be cut and as much as ten percent of the yarn wool, by far the most expensive element of the carpet, is wasted. Even with such high wastage it is impossible to eliminate the occurrence of low pile rows entirely or to ensure complete uniformity of the length of the individual pile yarns in each row.

It is the object of the present invention to substantially eliminate the waste of the pile yarn which presently occurs in Axminster looms.

It is another and important object of the present invention to provide an extremely high degree of uniformity in the length of the rows of pile yarn and in the length of the individual yarns, in each row.

' Still another important object is to provide an effective increase in the depth of the pile yarns of an Axminster carpet for a given length of yarn tufts by disposing a higher percentage of the tuft lengths above the carpet backing.

-Still another and important object is to achieve the results as aforesaid in a conventional Axminster loom without in any way affecting the mode of operation of the loom.

The principal feature of the invention resides in providing for the tensioning of each individual pile yarn during draw off to prevent its slippage.

More particularly according to the invention such tensioning is effected by converting the reed member of the loom into an effective yarn clamping as well as a weft beating mechanism by the provision of projecting means on the reed to engage over the breast plate. By the provision of a novel reed mechanism as aforesaid the desired tensioning of the individual yarn strands is effected yet the reed can be operated in the conventional manner without changing any of the other conventional mechanisms on the loom.

Moreover, by providing a reed structure as aforesaid the yarn is maintained tightly up against the wool shot following its being upturned by the comb and during retraction of the comb and while the subsequent weft shot is being beat up to hold the yarn. above the carpet backing so that a maximum pile depth for a given yarn length is obtained.

These and other features and objects of the invention will become apparent from the following description taken in conjunction with the accompanying drawings in which:

Figure 1 is apart side-elevational and part vertical sectional view of an Axminster loom embodying my invention.

Figure 2 is a fragmentary perspective view of the tube frame transfer mechanism reed and breastplate and illustrating the parts with the tube frame dipped to wipe in the pile yarn.

Figure 3 is a view similar to Figure 2 on an enlarged scale, but showing the reed swung to beat up the wool shot and the tube frame being lifted in the pile yarn drawn off.

Figure 4 is a fragmentary perspective view of the end release mechanism for releasably securing the tube frame to the tube frame chain.

Figures 5 to 13, inclusive are part-elevational, part vertical sectional views diagrammatically illustrating successive steps in the carrying out of the weaving of an Axminster fabric in accordance with the invention and showing the positions of the reed tube frame and comb relative to the breastplate in the carrying out of the invention with the loom illustrated in Figure 1.

Figure 14 is an enlarged fragmentary front-elevational view of the reed element of the loom of Figure 1, constructed in accordance with the invention.

Figure 15 is a vertical sectional view on the line 1515 of Figure 14.

Figure 16 is a top plan view, partly broken away, of the reed of Figure 14.

Figure 17 is a vertical sectional view of an alternative form of reed embodying the invention; and

Figure 18 is a top plan view, partly broken away, of the reed of Figure 17.

Referring first to Figure 1, the loom illustrated is, with the exception of the reed structure, generally designated at l, a conventional Axminster loom which operates to weave an Axminster fabric much more economically and efliciently than a conventional loom due to the cooperative action of the novel reed structure 1, breastplate 2, and comb 3, as will hereinafter be particularly described with reference to Figures 5 to 13, inclusive.

In addition to the reed, breast plate and comb elements above referred to, the loom includes the conventional elements comprising a lay swords 4, which carries the reed 1, heddles 5 for guiding and spreading the warp threads 6, needle 7, pile or tuft yarn feed and control mechanism generally designated at 8 and yarn cutting knives 9 and 10. The pile yarn feed and control mechanism 8 comprises the usual feed chain 11 which carries a series of tube frames 12 (one only being shown) which are held on the chain 11 by releasable spring clips 13 as shown in Figure 4.

The tube frame 12 carries a spool 14 on which the strands of pile or tuft yarn 15 are arranged and these strands extend down through a series of tubes 16 carried by the tube frame 12, the tubes being spaced apart for introduction between the warp threads 6 which are operated by the heddles 5 to form the warp shed through which the weft shot is passed by the needle 7. The tube frames in operation of the loom are removed from the chains 11 and carried downwardly to the wipe in position of Figures 2. and 5, and subsequently elevated to effect pile yarn draw off and then replaced onthe chains 11 by a tube frame transfer mechanism 17. v

The tube frame transfer mechanism 17 is pivoted at 18 and includes the usual clutch arms 19 for actuating the clips 13 and rocker arms 20 for engaging the tube frame when released to control the tube frame movement during wipe in and draw off in the convention-a1 manner. The tube transfer mechanism 17 is actuated by a rod 22 connected toa lever 23 carrying a cam follower 24 running on a cam 25 carried on the main drive shaft 26 of the The rocker arms (only one at one end of the tube transfer mechanism being shown) are actuated by a bell crank 27 coupled to a 'lever 28 by connecting rod 29, the lever 28 having cam'follower 30, again running on a cam 31 on the main drive shaft 26. The lay 4 of the loom is pivoted at 32 and is actuated by a lever 33 connected to the lay by connecting rod 34, the lever again having a cam follower 35 engaging a cam 36 secured on the main drive shaft.

The comb 3 has the usual composite motion being moved vertically by the comb put-up mechanism comprising a bell crank 37 connected on the one hand to an arm-38 carrying the comb by an adjustable connection 39 and having the other arm connected by a rod 40 to a lever 41 having a cam follower 42 engaging on a. cam 43 carried by the main drive shaft 26.

The comb put-out mechanism comprises the arm 38 pivoted to a lever 44 which in turn is connected to a lever 45 having a cam follower 46 operating on a cam '47 mounted on the main drive shaft of the loom by means .of a connecting rod 48.

The above recited loom instrumentalities operate in the conventional manner and, with the exception of the reed structure 1, are of conventional construction so that no further showing is deemed necessary for those skilled in the art. That is, the operation of the elements of the loom are conventional from the standpoint that, in a complete cycle of weaving, the pile yarn is introduced between the warp threads 6 by the tube frame 12 in the wipe in movement of the tube frame. Then the W001 shot, that is, the first shot of weft thread is passed through the warp sheds formed by the heddles and the reed structure 1 is actuated to beat up the wool shot against the fell of the cloth at which time pile yarn draw off takes place as the tube frame 12 is lifted by the tube transfer mechanism 17. Then, subsequently, the comb 3 is actuated to turn up the depending ends of the pile yarn 15 with the reed structure 1 retracted to allow the econd weft shot to be passed through the warp sheds.

The reed 1 is then actuated on its second beat up movement following severance of the pile yarn or tuft ends by the cutting knives 9 and 10. The second operation of the reed is to beat up the pile or tuft holding second shot, and the reed is again retracted to allow the third or backing weft shot to be passed through the warp shed and the reed is beat up for the third time in the cycle to beat up the backing shot to the fell of the cloth, the standard sequence in theweaving of an Axminister fab i The reed structure 1, shown in the loom in Figure 1, is according to the preferred form of reed shown in Figures 14 to 16, a structure comprising a suitable base or transverse support 49 carrying a plurality of upright fingers 50 which are arranged in parallel, equally spaced elationto receive the warp threads therebetween when in position on the loom. Each finger at its upper end is provided with a pin projection 51 extending laterally therefrom in the direction of the breastplate or breast beam 2 when the reed is mounted on the loom as shown in Figure 1. Each of these projections 51 has its outer end provided with a vertical or upright groove 52 adapted to receive the pile or tuft yarn 15 inserted between the warp threads in the wipe in movement of the tube frame 12- While the cyclic'movernent of the weaving elements of the loom is conventional, the cooperative action of the reed, comb, pile yarn feed and control mechanism 8 and breastplate 2 in carrying out the weaving is entirely distinctive as will be appreciated from the following detailed description with reference to the diagrammatic Figures 5 to 13, in which for sake of clarity the disposition of the warp threads forming the weave about the weft threads in the finished fabric has been omitted.

Referring first to Figure 5, it will be seen that the reed 1 is retracted and that the tube frame 12 is being actuated in the wipe in movement to introduce the pile yarn 15 between and below the warp threads 6, while the needle is delivering the wool shot 53 through the warp shed, the needle being operated through suitable cams, not shown, driven from the main drive shaft 26.

Figure 6 shows the progressive movement of the reed 1 together with the movement of the tubes 16 of the tube frame 12 in dash line showing, dash dot line showing, and solid line showing, respectively, as the wool shot is beat up to the fell of the fabric 54 on the breastplate 2. During this movement of the reed, the wool shot is forced toward the breastplate until the projections 51 of the'reed fingers 50 engage the depending ends of the pile yarn 15 at which time further movement of the reed effects advance of both the wool shot and the pile yarn towards the breastplate. In the final or limit position, the projections 51 of the reed fingers project over the leading edge 55 of the breastplate, and immediately thereabove, so that the pile yarn 15 is clamped beneath the wool shot 53 between the projections 51 and the breastplate 2, as will be seen in the solid line showing of Figure 6. The pile yarn 15 is sharply crimped as it follows around beneath the projections 51 up through the end grooves of the projections and back to the tubes 16 of the tube frame. The presence of the multiple bends in the yarn as it leads around beneath the pin projections 51, together with the clamping pressure exerted by the cooperating pin projections and breastplate serve to securely hold the yarn against displacement in the yarn draw 01f movement which occurs on lifting of the tube frame 12, in the subsequent movement of the tube transfer mechanism 17, as illustrated in Figure 7.

Since each pile yarn strand is clamped in the manner above described, each pile yarn strand is effectively tensinned and held against slippage in the yarn draw off step of Figure 7'. Since there is no danger of slippage of any of the pile y-arns held on the spool 14, the tension exerted on the spool to resist spool rotation by the control spring 56, see particularly Figures 2 and 3, can be materially increased from the permissible tension with conventional looms.

As a result of the ability to increase the tension on the spool 14, there will be no excessive run oif of the yarn during the yarn draw out, and the precise desired length of yarn can be drawnoff from the spool, so that when the pile yarn is cut off there will be the correct length of yarn depending from'the ends of the yarn tubes 16 for the subsequent wipe inaction.

Figure 8 illustrates the subsequent operation of turning up of the depending pile yarn ends following the yarn draw off. In this step the comb has been put out and put up as illustrated, and the reed 1 has been retracted to allow the subsequent or second weft shot 57 to be passed through the warp shed.

Figure 9 illustrates the next successive step in which, following turn up of the depending yarn ends around the wool shot 53 and While the reed is advancing the second shot 57 towards the breastplate, cut oil? of the yarn occurs by operation of, the knives 9 and 10. Since substantially the exact amount of yarn was introduced beneath the warp threads in the wipe in action of the tube frame because of the individual yarn control in the draw oif as above described, there will be substantially no yarn waste as the knives actuate to shave the tips of the upturned pile yarn and-the pile yarn reach 58 still connetced to the spool through the tube frame tubes 16.

In the conventional loom, due to the relatively light tension which can be applied to the spool 14 by the control spring 56 to prevent pulling out of a row or individual pile yarn strands in the draw 01f, an average extra length of yarn is drawn off from the spool during each loom cycle, which extra length is of the order of percent of the total length of the pile yarn tufts, and this length is cut off as waste in the step corresponding to the step of Figure 9. With the present invention, this waste is substantially eliminated.

Following the cut oif of the pile yarn the comb is taken down as the reed structure 1 heats up the second Weft shot 57 and the projections 51 on the reed fingers 50 perform their second function as they project over the descending comb to engage the turned up warp strands to prevent their falling back into the plane of the breastplate 2 and to force them fighter around the wool shot 53. This second function of the projections 51 then serves two purposes. The first purpose is to further tighten the pile strands around the wool shot 53 so that the pile or tuft of the finished fabric is maintained at the upper surface of the fabric to give maximum effective pile length for a given length of tuft yarn.

At the same time, the engagement and holding up of the turned up yarn or tuft ends ensures that the tufts will not drop out from between the wool and second Weft shot to give a low row or individual low pile strand along the row as the second shot is beat up. This action will be appreciated from the showings of Figure 10, and Figure 11 further shows that as the reed 1 approaches its limit position, the upturned tuft or pile ends are forced tightly around and back over the weft shot to further ensure that the pile or tufts are pushed upwardly to the top of the Axminster fabric.

Figures 12 and 13 illustrate the subsequent operation of introducing the third or backing shot through the shed of the warp threads 6, and this third shot, indicated at 59, is subsequently beat up by the reed which is then retracted in preparation for the subsequent cycle in which the pile yarn 8 is introduced in advance of the wool shot, as illustrated in Figure 13.

The function of the reed, therefore, in accordance with the present invention, is to provide a new control in the weaving action wherein the individual pile strands are clamped and tensioned against displacement during draw off and are maintained against displacement during drop out of the comb, and are subsequently pushed to the top of the fabric as the reed beats up the pile holding or second weft shot. As a result of the new weaving method achieved in placing the controls on the individual pile strands, not only is an Axminster fabric much more economically woven, but a superior disposition of the pile yarn is achieved to gain an effective increase in pile depth for a given length of pile yarn.

Figures 17 and 18 illustrate an alternative form of reed structure generally designated at 60, again comprising a plurality of upright, equally spaced parallel fingers 61 supported in spaced apart relation by a suitable transverse member 62. Secured to at least some of the fingers 61 and extending transversely of the finger row at one side thereof adjacent the tops of the fingers is a rod or wire 63. This rod of wire forms a lateral projection disposed on the side of the fingers adjacent to the breastplate of the loom with the reed in position, and the single rod or wire 63 performs in its function the function of the individual projections 51 of the reed structure of Figures 14 to 16.

It will be appreciated that other forms of reeds may be constructed to embody the invention, and that the details of the structures given herein are by way of specific illustrations of the invention, and not by way of limitation. It will therefore be obvious that other corresponding mechanisms may be resorted to in carrying out the invention, and that various modifications and alterations may be made without departing from the spirit of the invention as set forth in the appended claims.

What I claim as my invention is:

1. In an Axrninster loom having a breastplate, warp guiding heddles, a lay for carrying a reed to beat up weft shots towards said breastplate, a needle, pile yarn carrying tube frames, tube frame inserting and lifting mechanism for wiping in said tube frames to introduce pile yarn between warp threads passing to the heddles and to lift said tube frames to effect draw off of pile yarn, yarn cutting mechanism and a comb; the combination with said breast plate, heddles, lay, needle, tube frames, inserting and lifting mechanism, yarn cutting mechanism and comb, of a reed carried by said lay, said reed including a plurality of upstanding fingers, and means carried by said fingers adjacent the upper ends thereof and projecting laterally therefrom in the direction of said breastplate adapted to clamp pile yarn carried by said tube frames against said breastplateduring lifting of said tube frames.

2. A device as claimed in claim 1 in which said projecting means carried by said reed is adapted to overlie said breastplate with said reed swung to the extremity of its movement towards said breastplate during the beating up of a weft shot.

3. A device as claimed in claim 1 in which said pro jecting means comprises an individual projection on each of said fingers.

4. A device as claimed in claim 3 in which each of said individual projections is formed with a vertical groove adapted to receive wiped in pile yarn.

5. A device as claimed in claim 1 in which said projecting means comprises a rod secured to the upper ends and extending transversely of said fingers.

6. In an Axminster loom having a breastplate, warp guiding heddles for creating warp sheds, a needle for passing weft shots through the warp sheds, a lay for carrying a reed to beat up weft shots to said breastplate, pile yarn carrying tube frames, tube frame inserting and lifting mechanism for wiping in said tube frames to introduce pile yarn between warp threads passing to the heddles and to lift said tube frames to effect draw off of pile yarn, yarn cutting mechanism, a comb for turning up the ends of pile yarn introduced between warp threads around a Weft wool shot and drive means to drive said heddles, shuttle, lay, tube frame inserting and lifting mechanism and comb in the weaving of an Axminster carpet; the combination with said breat plate, heddles, shuttle, lay, tube frames, inserting and lifting mechanism, yarn cutting mechanism, comb and drive means, of a reed carried by said lay and comprising a plurality of upstanding fingers, one for each strand of yarn to be inserted between warp threads in the forming of an Axminster carpet, said fingers having adjacent their upper edges projecting means projecting laterally thereof towards said breastplate, said projecting means being adapted to cooperate with said breastplate on beating up of a weft Wool shot following introduction of pile yarn between warp threads by said r tube frame inserting and lifting mechanism to clamp each individual pile yarn against said breastplate and tension each pile yarn during yarn draw off, and, upon heating up a subsequent weft shot following pile yarn turn up by said comb, to engage over said comb and hold each individual yarn in turned up position during comb withdrawal following yarn turn up.

7. A reed structure for an Axmi'nster loom comprising a plurality of substantially identical upright fingers arranged in parallel equally spaced relation to form a longitudinal row, means supporting said fingers in said parallel spaced apart relation, and a laterally projecting formation on said fingers adjacent the upper ends thereof projecting laterally from one side of said row, said laterally projecting formation being adapted to cooperate with a breastplate of an Axminster loom for clamping pile yarn during yarn draw off.

8. A reed as claimed in claim 7 in which each individual finger is formed with a lateral projection to form said laterally projecting formation.

9. A reed as claimed in claim 7 in which said laterally projecting formation comprises a rod extending longitudinally of said finger row on one side of said row adjacent the upper ends of said fingers, said rod being secured to at least certain of said fingers.

10. In an Axminster loom having a breastplate on which the fell of a cloth is adapted to be formed, the combination with said breastplate of a reed and a lay for actuating said reed to a limit position adjacent said breastplate to beat a weft shot towards said breastplate, said reed comprising a plurality of equally spaced parallel upright fingers, said fingers carrying means adjacent their upper ends to immediately overlie said breastplate with said reed swung to said limit position.

11. In an Axminster loom having a breastplate and a lay, the combination with said breastplate and lay of 'a reed structure carried by said lay, said reed structure comprising a plurality of equally spaced parallel upright fingers each having a latter projection adajcent the upper end thereof, said lay being adapted to actuate said reed to beat up a weft shot towards said breastplate and to move said reed to a limit position adjacent to said breastplate, said finger projections with said reed in said limit position engaging over said breastplate. and disposed immediately thereabove to form with said breastplate opposing clamp elements adapted to clamp pile yarn during yarn draw off in the weavin g of Axminster fabric.

12. In the weaving of Axminster fabric, the steps of wiping in pile yarn between sheds of warp thread to leave a series of pile yarn ends projecting below the warp threads, introducing a first weft shot through the warp sheds, beating up the weft shot to the fell of the fabric, clamping the individual pile yarns beneath said weft shot while drawing off a predetermined length of pile yarn, combing said pile yarn ends up tightly around said weft shot, cutting said pile yarn while combed up around said weft shot to form pile tufts, introducing a second weft'shot through the warp sheds, beating said second shot up and clamping said upturned yarn ends down against said first weft shot, introducing a third weft shot between the warp sheds and beating up said third weft shot.

'13. A method as. claimed in claim 12in which the upturned yarn ends are forced upwardly. and forwardly over the first weft shot as said second weft shot moves into its final beat up position. 7 j

14. In the weavingof an Axminster fabric in an Axminster loom, the steps of wiping in each pile yarn carrying tube frame to a position clear of vthe beat up path of the reed with the individual tubes of the frame through which the pile yarn extends disposed betweensheds of warp thread to present depending lengths of pile yarn below the warp threads, introducing a first weft shot.between the warp sheds, beating up the weft shot to the fell of the cloth being formed on thebreastplate andas the weft shot reaches the fell of the fabric forcingthe individual depending pile yarns forward over the breastplate and clamping said individual yarns down against said breastplate, drawing off a predetermined length of pile yarn from the tube frame with said individual yarns clamped, advancing the comb to turn up the depending pile yarn ends around the weft shot, cutting off the pile yarn from the tube frame, introducing a second Weft shot through the warp sheds, beating up said second weft shot towards the fell of the fabric, withdrawing the comb out of the path of the reed as said second weft shot is beat up and while the comb is commencing to be withdrawn engaging the turned up pile yarn ends over the top of the comb to retain them in upturned position and as the second weft shot reaches the fell of the fabric forcing said upturned pile yarn ends upwardly and forwardly over the first weft shot, and finally introducing a third weft shot between the warp sheds and beating up said third weft shot.

References Cited in the file of this patent UNITED STATES PATENTS 

